STC Smartscan NG2 User manual

Smartscan NG²
Wayside Enclosure
Components
"Wayside Enclosure Components" refer to those SmartScanNG² detector subsystems that are
typically contained within the equipment bungalow. These components include:
SmartScanNG² Controller
Power Subsystem
AEI Subsystem
Temperature Probe
This manual provides an overview of these subsystems as well as detailed procedures for site
preparation, installation, and placing a system into service.
EUD-2018086-00
Rev. 3
May 14 2021

© 2021 Southern Technologies Corporation (STC). All rights reserved. Printed in the USA.
Because products evolve and system configurations change, this manual may not be an exact
representation of the products and systems that you are using.
STC assumes no responsibility for errors or omissions in this document. Nor does STC make
any commitment to update the information contained herein.
Product and company names mentioned herein are trademarks or registered trademarks of
their respective owners.
WARNING!
Contact with electrically active parts could result in sparks, burns, and electric shock.
Because of this, you should avoid all electrical hazards when installing,
wiring, operating, and maintaining the SmartScanNG² system. Failure to do so could
result in damage to the equipment or serious injury to you.
NOTICE:
If equipped with an AEI subsystem, the user is required to obtain a Part 90 site
license from the FCC to operate in the United States. See product label for FCC ID
number. Access the FCC Web site at www.fcc.gov/Forms/Form601/601.html for
additional information concerning licensing requirements.
Users in all countries should check with the appropriate local authorities for licensing
requirements.
6145 Preservation Drive, Chattanooga, TN 37416
web: www.southern-tech.com
email: stce[email protected]
fax number: 423-499-0045
telephone number: 423-892-3029

EUD-2018086-00 Rev.3, SmartScanNG² User's Guide for Wayside Enclosure Components, 14 May 2021 3
Contents
This section lists the headings of this guide in sequential order with their page references.
Contents...................................................................................................................... 3
1.0 Introduction........................................................................................................... 7
1.1 Purpose of This Guide................................................................................................7
1.2 SmartScanNG² - Wayside Enclosure Components.....................................................7
1.3 Cautions.....................................................................................................................7
1.4 Disclaimers.................................................................................................................8
1.5 How to Comment on This Guide.................................................................................8
1.6 How to Order More Copies of This Guide...................................................................8
1.7 Standard Warranty .....................................................................................................9
2.0 SmartScanNG² Detector..................................................................................... 11
2.1 Controller Module (2300-602)...................................................................................12
2.1.1 Display Panel...................................................................................................13
2.1.2 Processor Modules..........................................................................................15
2.1.3 System Interface Board (2300-110).................................................................16
2.1.4 Velocity IP Device Manager.............................................................................18
2.1.5 Controller Module Connector Panel.................................................................19
2.2 2300-601 NG² Chassis Assembly.............................................................................21
2.2.1 System-Interconnect Board (2300-107)...........................................................21
2.2.2 SOTC Board (Zepic III or Zepic PD8-Plus).......................................................23
2.2.3 Connector Panel..............................................................................................23
2.2.4 Solid-State Relays...........................................................................................25
2.2.5 Radio...............................................................................................................25
2.2.6 Other Components ..........................................................................................28
2.2.7 DC Power Switch.............................................................................................28
2.2.8 External Radio Connector................................................................................29
2.2.9 Chassis Mounted LEDs ...................................................................................30
2.3 2300-501 NG Chassis Assembly..............................................................................32
2.3.1 Surge-Protection Panel....................................................................................33
2.3.2 SOTC Board (Zepic PD8-Plus)........................................................................34
2.3.3 Relay Panel.....................................................................................................34
2.3.4 Radio...............................................................................................................35
2.3.5 Other Components ..........................................................................................38
2.3.6 DC Power Switch.............................................................................................38
2.3.7 External Radio Connector................................................................................39
2.3.8 Chassis Mounted LEDs ...................................................................................40
3.0 Surge Panel......................................................................................................... 41
3.1 Surge Panel Assembly.............................................................................................41
4.0 Power Subsystem............................................................................................... 43
4.1 12 VDC Power Subsystem.......................................................................................43
4.1.1 Battery.............................................................................................................43
4.1.2 Battery Charger ...............................................................................................44
4.2 24 VDC Power Subsystem.......................................................................................45

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4.2.1 Battery..............................................................................................................45
4.2.2 Battery Charger................................................................................................46
4.3 DC Power Distribution...............................................................................................47
5.0 Shielded Temperature Probe..............................................................................49
6.0 AEI Subsystem ....................................................................................................51
6.1 2300-752 MPR(x) Panel............................................................................................51
6.1.1 MPRR ..............................................................................................................53
6.1.2 MPRX...............................................................................................................54
6.1.3 DC-DC Converter.............................................................................................55
6.1.4 DB9 Breakout Board ........................................................................................55
7.0 Wind Monitor........................................................................................................57
7.1 RM Young Wind Monitor.....................................................................................57
7.2 2300-220 Wind Monitor Interface........................................................................57
7.3 2300-220 Wind Monitor Wiring............................................................................58
7.4 NG² J3 Jumper Settings for RS485 Communications..........................................60
7.5 Wind Monitor Setup.............................................................................................60
8.0 Preparation...........................................................................................................61
8.1 Selecting a Site.........................................................................................................61
8.2 Preparing the Scanner Location................................................................................61
8.3 Preparing the AEI Antenna Masts.............................................................................62
8.4 Preparing the Wayside Enclosure.............................................................................64
8.5 Receiving Your System.............................................................................................66
8.6 Returning Damaged or Defective Hardware..............................................................66
8.7 Getting Help with the Installation...............................................................................66
8.8 Identifying the Installation Tools................................................................................67
9.0 Installing Wayside Enclosure Components......................................................69
9.1 Grounding System....................................................................................................69
9.2 SmartScanNG² Detector...........................................................................................69
9.3 Battery Charger.........................................................................................................70
9.4 Fuse Block................................................................................................................72
9.5 Power Subsystem.....................................................................................................73
9.6 Bearing Scanners .....................................................................................................75
9.7 Wheel Scanners........................................................................................................76
9.8 Track Wiring for the 2300-601 NG² Chassis..............................................................77
9.8.1 Gating Transducers..........................................................................................80
9.8.2 Advance Transducers ......................................................................................81
9.8.3 Dragging-Equipment Detector..........................................................................81
9.8.4 High-Load/High-Wide Detector.........................................................................81
9.8.5 Shielded Temperature Probe ...........................................................................82
9.9 Track Wiring for the NG Chassis...............................................................................84
9.9.1 Gating Transducers..........................................................................................85
9.9.2 Advance Transducers ......................................................................................86
9.9.3 Dragging-Equipment Detector..........................................................................86
9.9.4 High-Load/High-Wide Detector.........................................................................87
9.9.5 Shielded Temperature Probe ...........................................................................88
9.10 External Presence Detector (optional).....................................................................90
9.11 Presence Out..........................................................................................................91
9.12 Radio Antenna........................................................................................................92

EUD-2018086-00 Rev.3, SmartScanNG² User's Guide for Wayside Enclosure Components, 14 May 2021 5
9.13 MPRR/MPRX Panel ...............................................................................................93
10.0 Placing a System into Service......................................................................... 95
10.1 Checking the Trackside Components.....................................................................95
10.2 Checking the Wayside Enclosure Components......................................................96
10.3 Powering-up the SmartScanNG² System................................................................97
10.4 Checking the Scanner Shutters............................................................................102
10.5 Calibrating Scanners............................................................................................104
10.5.1 Bearing Scanners........................................................................................104
10.5.2 Wheel Scanners ..........................................................................................109
10.6 Configure the Drive Frequency of a PD8-Plus......................................................111
10.7 Calibrating the PD8-Plus Presence Detector........................................................112
10.8 Checking the Broadcast........................................................................................114
10.9 Checking the Speech Data...................................................................................116
10.10 Generating Test Trains.......................................................................................117
10.11 Setting Transducer Gain.....................................................................................119
10.12 Doing the Final Activities ....................................................................................121
11.0 Customer Service ........................................................................................... 129
11.1 Reaching STC......................................................................................................129
11.2 Returning Equipment for Repair ...........................................................................129
11.3 Reporting Problems or Suggestions.....................................................................130
11.4 Ordering Spare Parts............................................................................................130
11.5 Checking on Shipments and Orders.....................................................................130
Index ........................................................................................................................ 131

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EUD-2018086-00 Rev.3, SmartScanNG² User's Guide for Wayside Enclosure Components, 14 May 2021 7
1.0 Introduction
This section summarizes the purpose of this guide, describes the SmartScanNG² system, tells
how to comment on this guide, tells how to order more copies of this guide, and covers STC's
standard warranty. It also covers the cautions and disclaimers of which the customer should
be aware of.
1.1 Purpose of This Guide
The technical staff at Southern Technologies Corporation (STC) created the SmartScanNG²
defect detection system. It is designed to monitor moving trains and report certain conditions
detected on these trains. The SmartScanNG² system is modular and firmware-driven.
Hardware and firmware can be changed to meet the unique needs of a given railroad. Thus,
some of the components that make up a SmartScanNG² system differ from railroad to railroad.
This guide covers the portion of the SmartScanNG² system that is housed within the wayside
enclosure. It describes the functionality, installation, and operation of these components.
1.2 SmartScanNG² - Wayside Enclosure Components
In this guide, the structure that houses the SmartScanNG² is called the "wayside enclosure."
This structure, which comes in many shapes and sizes, can be any appropriate waterproof
enclosure located adjacent to the tracks. It goes by many other names, such as bungalow,
location case, apparatus housing, and equipment enclosure.
Attached to the inside of most wayside enclosures is:
• One SmartScanNG² detector per track
• One power subsystem per SmartScanNG² detector
Attached to the outside of most wayside enclosures is:
• One antenna per radio
• One shielded temperature probe per SmartScanNG² detector
1.3 Cautions
Contact with electrically active parts could result in sparks, burns, and electric shock. Because
of this, you should avoid all electrical hazards when installing, wiring, operating, and
maintaining the SmartScanNG² system. Failure to do so could result in damage to the
equipment or serious injury to you.

814 May 2021, SmartScanNG² User's Guide for Wayside Enclosure Components, EUD-2018086-00 Rev.3
In operation, batteries generate and release flammable hydrogen gas, which, if ignited by a
burning cigarette, naked flame, or spark, may cause battery explosion with a dispersion of
casing fragments and corrosive liquid electrolyte. So, carefully follow the manufacturer's
instructions. Keep all sources of gas ignition away from the batteries and do not allow metallic
articles to contact the negative and positive terminals of a battery at the same time.
Do not install any tower, pole, mast, or antenna on a wet or windy day. Do not install them
near any type of power line. Be sure all parts of the system are out of falling range of any
overhead wires, including the lead to any building. Once installed, do not climb any tower,
pole, or mast. Failure to follow these instructions could result in injury or death.
1.4 Disclaimers
The correct use of this guide, the environmental conditions at the time of installation, the
method of installation itself, and the installation of customer-supplied components are beyond
the control of STC. So too are the correct use and maintenance of all or part of the
SmartScan system. Therefore, the installer, user, and maintainer must assume the risk of any
injury that might occur during installation, use, and maintenance of all or part of the SmartScan
system. STC assumes no risk, liability, or responsibility for errors and omissions on the part of
the installer, user, or maintainer.
1.5 How to Comment on This Guide
We want to hear from you. Tell us what you like or don't like about this guide. Send your
comments to:
Southern Technologies Corporation
Technical Publications Department
6145 Preservation Drive
Chattanooga, Tennessee 37416-3638
USA
All comments become the sole property of STC, and none will be returned.
1.6 How to Order More Copies of This Guide
When placing an order for more copies of this guide, refer to the order number shown on the
cover of this guide. To request pricing and delivery, call 423-892-3029, fax 423-499-0045, or
available.

EUD-2018086-00 Rev.3, SmartScanNG² User's Guide for Wayside Enclosure Components, 14 May 2021 9
1.7 Standard Warranty
Systems manufactured by Southern Technologies Corporation carry a 14-month warranty from
the date of shipment. Warranty is limited to repair or replacement at the sole discretion of
STC, of any goods found to be defective in either materials or workmanship during the 14-
month period following shipment. Warranty does not apply to a product with signs of obvious
abuse or a product that has been improperly installed.
STC warrants that goods represented by this warranty statement have been designed and
manufactured with all reasonable care and attention to appropriate regulatory documents.
STC makes no representation that the goods covered by this warranty are suitable for the
application they are used for. Application of the goods is at the sole discretion of the
purchaser.
Purchaser is responsible for shipment of the defective product to STC. STC will pay the return
shipping charges.
Products purchased from other vendors but included in STC systems carry the original
manufacturer's warranty, typically 12 months. Warranty claims for these products must be
made directly to the original equipment manufacturer.

10 14 May 2021, SmartScanNG² User's Guide for Wayside Enclosure Components, EUD-2018086-00 Rev.3

EUD-2018086-00 Rev.3, SmartScanNG² User's Guide for Wayside Enclosure Components, 14 May 2021 11
2.0 SmartScanNG² Detector
SmartScanNG² Detector
There is one SmartScanNG² Detector per track. At double-track sites the one on the left
supports track1, and the one on the right supports track2.
The two major components of the SmartScanNG² Detector are the Controller Module and the
Chassis Assembly.
NG²Controller Module
2300-602
NG²Chassis
2300-601
Display Panel
COM Ports
Status LEDs
Connector Panel
This figure depicts an NG² Controller Module mounted to a 2300-601 NG² Chassis.
CONTROLLER MODULE
PANEL COVER
COM1
EXTERNAL RADIO CONNECTOR
ON/OFF DC POWER SWITCH
This figure depicts an NG² Controller Module mounted to an older generation 2300-501NG
Chassis.

12 14 May 2021, SmartScanNG² User's Guide for Wayside Enclosure Components, EUD-2018086-00 Rev.3
The power cord at the bottom of the Chassis Assembly powers the heaters in the 2500-512AC
scanner. This cord should be plugged into a grounded three-wire 120-volt outlet. The
minimum operating voltage is 110 volts. Plugging the cord into an outlet of more than 128-
volts will severely damage your system.
If 2500-512DC scanners are used, there usually isn't a power cord at the bottom of the
enclosure. If one is present, don't plug it into an outlet because the heaters in these scanners
use 12 VDC.
2.1 Controller Module (2300-602)
The Controller module is the brains of the SmartScanNG² system. It contains the Interface
board, the display panel, and the optional Velocity IP Device Manager. For ease of
maintenance, the module detaches from the SmartScanNG² detector as a separate unit. It is
easily removed by first unplugging the Molex and ribbon cable connectors and then by
removing the fasteners.
Communications with the controller module can be established locally via:
Serial Interface through the local comm port
WIFi Interface (wireless connection)
Display panel/keypad on the front of the controller module
Communications with the controller module can be established remotely via:
Web Interface with an internet connection
Serial Interface through Telnet connection
Serial Interface through a hardline or cellular modem
The figure below shows the major parts of the Controller module (2300-602).
Interface Board
Controller Module Cover
Controller Module Base
Velocity Modem Board
WiFi Antenna
Status Panel

EUD-2018086-00 Rev.3, SmartScanNG² User's Guide for Wayside Enclosure Components, 14 May 2021 13
2.1.1 Display Panel
Located on the front of the SmartScanNG² Controller Module is the Display Panel. Its status
indicators and display module provide a snapshot of the overall system health. As a
convenience, the Display Panel also provides a user interface to execute some frequently
used system functions (i.e., Auto Cal, Radio Test, etc.).
The display panel consists of 6 LEDs, a keypad, and an LED display as shown below.
FUNC SELECT RESET
18-111-011 Rev.C
TO1
TO2 COP-A
COP-B PTT
SYS WARN
LED
Meaning when Lit
TO1
Indicates wheel sensor TO1 is active.
TO2
Indicates wheel sensor TO2 is active.
COP-A Indicates the status of Processor-A. If the CPU is running its program
correctly, the LED blinks on and off. If the program isn't operating as
expected, the LED is lit
solid
or
isn't lit
at all.
COP-B Indicates the status of Processor-B. If the CPU is running its program
correctly, the LED blinks on and off. If the program isn't operating as
expected, the LED is lit solid or isn't lit at all.
PTT
Indicates the radio PTT is active.
SYS WARN
Indicates a system warning has
been detected
.
Keypad Switch
Function
FUNC The function key toggles from home screen to the Main Menu. It also
serves as "Back" key in the system submenus to return to the previous
menu level.
▼
(Arrow Down)
Scroll down menu options.
▲ (Arrow Up) Scroll up menu options.
SELECT
Selects
the
highlighted
menu
option.
RESET Initiates system reset.
MP 1234.5 02:05:39
Temp: 72

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LED Display:
The display assembly includes a 4-line 20-character OLED display and a five-key
membrane switch panel. If unused for five minutes, the display will time out to conserve
power. Press any key to turn the display back on.
The home screen displays milepost, time, and temperature.
Menu Navigation:
Press the FUNC key to toggle from the home screen to the Main Menu or to back out
of the various submenus.
Use the ▲UP and ▼DOWN keys to move the ► pointer next to the desired menu
option.
Press the SELECT key to choose the menu option. The "↓" symbol on the display
screen indicates that there are more options available if you scroll down. Likewise, the
"↑" symbol indicates more options are available if you scroll up.
System Functions
Various system functions can be performed from the display panel, such as:
Radio Test
Auto Cal
Network Menu
Radio Menu
Volume Menu
Some functions are customer-specific. Refer to your Operator's Guide for detailed
information about those functions available through the system's Display Panel.
Main Menu
Sys. Health Menu
►Reset Sys. Health
↓Radio Test
MP 1234.5 02:05:39
Temp: 72

EUD-2018086-00 Rev.3, SmartScanNG² User's Guide for Wayside Enclosure Components, 14 May 2021 15
2.1.2 Processor Modules
Running programs written by STC, the processor modules control the entire SmartScanNG²
system. There are two independently operating processor modules, the Analyzer Processor
and the Communications Processor. The Analyzer Processor (Processor-A) is responsible for
data retrieval from external sources, such as the shielded temperature probe, scanners,
transducers, and auxiliary devices. The Communications Processor (Processor-B) is used to
process and store the retrieved data. It then presents information to the user in the form of
reports.
Processor-A initially stores train data in static random-access memory (SRAM) on the
processor module. After train passage, Processor-B moves this data to a nonvolatile Flash
memory for long-term storage. This memory contains:
The Trains directory, which contains data on each new train that passes the site. The
Train Summary report and Train Detail report get their data from this directory.
The Exceptions directory, which contains data on each train that has one or more
Exception Alarms or System Alarms. The Exception Summary report and Exception
Detail report get their data from this directory.
Each directory is organized as a circular buffer. In this scheme, data is added to the directory
until the directory is full. Once full, the oldest data in the directory is overwritten as new data is
recorded. The buffer for the Trains directory holds data on about 140,000 axles, but no more
than 100 trains. The buffer for the Exceptions directory holds data on about 4,500 axles, but
no more than 50 trains.

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2.1.3 System Interface Board (2300-110)
As its name implies, all of the interface and signal conditioning circuitry is located on the
Interface board. This board connects to the System-Interconnect board with a 60-position
ribbon connector and an 8-position Molex connector, which is shown below.
The board operates from an unregulated battery voltage of 9VDC to 30VDC. The power input
circuitry includes radio-frequency interference suppression, voltage surge protection, open
fuse LED indicator, a self-restoring fuse, and reverse polarity protection. The board produces
regulated 3.3VDC, -5 VDC, regulated +5 VDC, regulated +12 VDC, and regulated +15 VDC to
power the on-board circuitry, Velocity Board, and external scanner circuitry.
The figure below shows the System Interface board (2300-110). The board is shown as one
would see it in service, which is the normal orientation for the board on a properly installed
system.
Analyzer
Comm

EUD-2018086-00 Rev.3, SmartScanNG² User's Guide for Wayside Enclosure Components, 14 May 2021 17
Potentiometer R19
Potentiometer R19 adjusts the incoming touchtone volume. It is set at the factory and should
not be changed by the customer.
Potentiometer R34
Potentiometer R34 adjusts the audio level (modulation) going to the radio. A misadjusted level
will be distorted or very weak sounding. This adjustment is set at the factory to FCC
specifications. Turn R34 clockwise to increase the audio level. Turn it counterclockwise to
decrease the audio level.
LED 6
The Interface board (2300-110) has a red LED labeled LED6. This LED lights when the self-
restoring fuse F1 opens due to an overcurrent condition on the +12-VDC supply voltage input.
LED 7
The Interface board (2300-110) has a red LED labeled Valid DTMF (also labeled LED7). If
R19 is adjusted properly, this LED lights as valid touchtones are received from the radio.
LED 8
The Interface board (2300-110) has a red LED labeled LED8. This LED lights when the
dragger (aka dragging-equipment detector) input activates.
LED 9
The Interface board (2300-110) has a red LED labeled LED9. This LED lights when the high-
load input activates.
LED 10
The Interface board (2300-110) has a red LED labeled LED10. This LED lights when the
wide-load-1 input activates.
LED 11
The Interface board (2300-110) has a red LED labeled LED11. This LED lights when the
wide-load-2 input activates.

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2.1.4 Velocity IP Device Manager
The Velocity IP Device Manager lets the system (at the site) communicate with a computer
(away from the site).
The figure below shows a Velocity IP Device Manager.
DS6
DS1
DS5
DS2
DS1
U1
J3
DS2
BH1
1
2
J8
Power Jack (J8)
The power jack is used to supply 9 VDC to the Velocity. A power cord connects the power
jack to P13 on the Interface board.
Port 1 Connector
The Port 1 connector connects the Velocity IP Device Manager to the rest of the system. A
standard 10-position ribbon cable connects Port 1 of the Velocity to P7 on the Interface board.
Port 2 Connector
The Port 2 connector connects the Velocity IP Device Manager to the outside world. Port 2
on the Velocity IP Device Manager connects to COM6 on the right edge of the Controller
module. (You would normally plug your computer into COM6 to access the Velocity's
instruction set and database.)

EUD-2018086-00 Rev.3, SmartScanNG² User's Guide for Wayside Enclosure Components, 14 May 2021 19
Battery (BH1)
During a power interruption to the Velocity IP Device Manager, the on-board coin cell battery
keeps the internal real-time clock running. During a power interruption, if this battery is low,
dead, or missing, the stored time and date is lost. However, no train data is lost.
Status LEDs
On the Velocity IP Device Manager are 6 status LEDs. The table below describes what each
lit LED means.
LED
Meaning When Lit
12V Lights when the Velocity IP Device Manager is getting adequate DC power from the
SmartScanNG²
system.
3.3V Lights when the onboard 3.3-VDC regulator is working.
5V
Lights when
the onboard 5
-
VDC
regulator is working.
ACT Flashes when there is activity on the Ethernet connection. That is, it flashes when
sending or receiving data.
HB
Flashes
once a second
when
the Velocity
IP Device Manager
is running properly.
LNK
Lights when
an Ethernet
connection
is made
.
2.1.5 Controller Module Connector Panel
On the right side of a mounted Controller module (2300-602) are a group of connectors, as
shown below.
COM1
COM2
COM3/Velocity
COM4
COM5
COM6
Molex Conn
Ethernet
RS485
Velocity

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Serial Ports
On the right side of a mounted Controller module are five serial ports. They are labeled
COM1, COM2, COM4, COM5, and COM6.
The table below describes the use of each serial port.
Port
Use
COM1 Used to communicate with a customer-provided external device. At single-track
sites, a computer is normally connected here. At double-track sites, a null-modem
cable is attached from COM4 of system1 (that is, the system with an installed
modem) to COM1 of system2 (that is, the system without an installed modem).
COM1
is connected
to
P6
on the Interface board.
COM2
Currently unused
.
COM4
Currently unused.
COM5 Used to connect the AEI reader (2300-750 or MPRX) to the SmartScanNG²
system.
COM5
is connected
to
P8
on the Interface board.
COM6
Currently unused.
Ethernet Connection (RJ45 Jack)
There are two Ethernet connectors on the right side of a mounted Controller module (2300-
602). The Velocity (located between COM2 and COM4) and the Ethernet (located at the right-
side bottom).
The Velocity connector is connected internally to the Velocity IP Device Manager (if so
equipped). The Velocity is a data harvesting tool that reports to central office systems.
The Ethernet connector provides IP connectivity and allows for remote access via Telnet or
Web User Interface.
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